Effect of mixing temperature on microstructure of an Al-Si alloy prepared by controlled diffusion solidification

The effects of mixing temperature, i.e., the temperatures of two precursor melts(pure Al and Al-12Si), on the temperature and solute fields of resultant mixture, the nucleation and growth, and the size and morphology of primary grains during controlled diffusion solidification(CDS) of Al-8Si alloy were investigated by using simulation and calculation. The results indicate that a lower mixing temperature is helpful for achieving more supercooled microscale Al-rich pockets in the mixture, and increasing the width and supercooling degree of supercooling zone in the Al-rich pockets, and thus, the nucleation rate. The nuclei grow up in nondendritic mode, resulting in spheroidal, at least, nondendritic grains. In a successful CDS, the superheat degrees of the two precursor melts should be limited within several degrees, and it is not necessary to extra stipulate the superheat degree of target alloy melt(Al-8Si) when the requirement about Gibbs energies of the three melts is matched. Subsequent observation on casting microstructures shows that the employed simulation and calculation processes are reasonable and the achieved results are reliable.